Modular Stair Tread Overlay

ABSTRACT

A modular stair tread overlay including a tread and a front nosing attached to a front edge of the tread cover is disclosed. The front nosing is attached to a front edge by a securing means such as a tongue and groove joint to providing a strong mechanical joint between the nosing portions and the tread cover. Adhesive may be applied at the tongue and groove joint to enhance the strength of the joint. The front nosing of the modular stair tread is hollow thereby allowing the installation of the stair tread overlay over the original stairs without the requirement of removing or trimming the nose of the original stair treads. The stair tread and the nosing can also be unitary and be made of material such as metal, plastic or composite. A method for remodeling stair sets is also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present patent application claims the benefits of priority of United State Provisional Patent Application No. 61/739,777, entitled “Modular stair tread overlay”, and filed at the United Stated Patent Office on Dec. 20, 2012, the content of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to stair tread overlay systems and methods.

BACKGROUND OF THE INVENTION

The use of stair tread overlay is well known in the art and many different designs have been proposed. Stair tread overlay may be used for rebuilding stair sets without having to invest the important sum of money required to manufacture full wood stairs. As such, using stair tread overlay, over composite or lower quality wood allows the homeowner to build a stair case that looks as if solid wood stairs had been used.

The home improvement warehouses are filled with several types of stair tread overlay systems. While several systems are available, most of the available systems require the installer of the stair tread overlay to trim the existing treads using various kind of saw. Such trimming of the tread is required in order to fit the stair tread overlay. The trimming of the nose allows the new stair tread nose to fit onto the original riser without any hollow spaces.

In addition, stair tread overlay systems are also used by homeowner desiring to improve the looks of their old stair treads. Most of the existing systems comprise a tread and a nosing secured together by tongue and groove. In addition, some systems also comprise risers thereby entirely covering the previous staircases.

As mentioned above, many designs are known in the art. However, the use of previously disclosed systems generally requires significant skills for their installations thereby also increasing the stair set makeover costs. In addition to requiring significant skills from the installer, the trimming of the original stair treads also make a significant amount of damages to the existing installations. The installation of previous stair systems may even in some instances require as many tool as building a new stair set.

SUMMARY OF THE INVENTION

The present invention relates to stair tread overlay systems and methods. The present invention will disclose a modular stair tread overlay that will at least mitigate some of the short comings of previously known systems. As such it will teach substantial improvements in the construction and installation of stair treads overlay.

As such, a system and method in accordance with the principles of the present invention will generally increase the ease of installation of the stair tread overlay system thereby increasing the spectrum of homeowners able to install such system by themselves. Moreover, the present system will disclose a more versatile system and method allowing the owner to customise the modular stair tread overlay according to the desired style and model.

In the present embodiment, the modular stair tread overlay system allows homeowners to remodel their stair set with minimal knowledge or skills in home improvement. The modular stair tread overlay generally comprises a stair tread cover and a two pieces nose capping portion. In addition, the stair tread overlay may comprise a riser cover. As such it is possible to have the modular stair tread overlay system entirely covering the original stair set.

In one aspect of the invention described therein, the modular stair tread overlay system is typically designed in three pieces, the stair tread and the two pieces nose capping portion. This configuration of modular stair tread overlay system typically allows the covering of most type of stair tread without requiring any removal of the original tread nose.

In a further aspect of the invention described therein, the modular nature of the stair tread overlay allows it to be manufactured in various materials at a fairly affordable price. The modular nature of the invention will also make the stair tread overlay interchangeable to different looks and model without significant efforts. The low cost to manufacture the product is significant due to the fact that this modular stair tread overlay remodelling solution must be at least more affordable than the original solid wood stairs.

Typically, the modular stair tread overlay system is installed over the original solid wood stair treads. However, the present stair tread overlay may also be designed to cover most already recovered stair treads. For instance, in one embodiment, the stair tread overlay could be used to remodel a carpet covered stair set. In this typical case, the customer would choose the tread overlay and according to the size of the original tread nose, including the carpet thickness, choose the two pieces nose capping accordingly.

Moreover, this novel stair tread overlay system will allow homeowner to transform the older fashion stair sets into different more modern styles such as a contemporary thicker stair set. This kind of product will also be convenient for home sellers or brokers. They will be able to transform the look of the older looking stair sets in newer more contemporary stairs in a substantially shorter time than the usually required time to remodel a stair set.

As a result, it can be of substantial advantage to have the system installed over the previous stairs wherein the system does not require the removal of any original stair tread nose. In addition, the stair tread overlay pieces can be configured with an interlocking mechanism thereby also reducing the required tools and materials for installation.

Other and further aspects and advantages of the present invention will be obvious upon an understanding of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice.

The features of the present invention which are believed to be novel are set forth with particularity in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features and advantages of the invention will become more readily apparent from the following description, reference being made to the accompanying drawing in which:

FIG. 1 is a cross sectional view of an original stair set.

FIG. 2 is a cross sectional view of a stair set remodelled with a modular stair tread overlay.

FIG. 3 is an enlarged view of two stairs of the stair set of FIG. 2.

FIG. 4 is a cross sectional view of the stair set of FIG. 3 wherein the first nose capping portion is rounded.

FIG. 5 is a cross sectional view of the stair set of FIG. 3 wherein the first nose capping portion has chamfers.

FIG. 6 is a cross sectional view of the stair set of FIG. 3 wherein the first nose capping portion is squared.

FIG. 7 is a cross sectional view of the stair set of FIG. 6 with a larger first nose capping portion.

FIG. 8 is a cross sectional view of the stair set of FIG. 7 with a larger first nose capping portion.

FIG. 9 is a cross sectional view of the stair set of FIG. 3 wherein the first nose capping portion is reinforced.

FIG. 10 is a cross sectional view of the stair set of FIG. 9 with a larger first nose capping portion.

FIG. 11 is a side view of a stair set recovered with a modular stair tread overlay.

FIG. 12 is a cross sectional view of a stair set recovered with a two pieces modular stair tread overlay.

FIG. 13 is a cross sectional view of a stair set recovered with a singular piece modular stair tread overlay.

FIG. 14 is a cross sectional view of the stair set of FIG. 3 wherein the first and second nose capping portions are connected to using interlocking mechanism.

FIG. 15 is zoomed view of a stair set of FIG. 14.

FIG. 16 is a top view of a turning stair set.

FIG. 17 is a side view of the modular stair tread overlay for the first stair of the turning stair set of FIG. 16.

FIG. 18 is a top view of the first stair of the turning stair set of FIG. 16.

FIG. 19 is a side view of the modular stair tread overlay for the second stair of the turning stair set of FIG. 16.

FIG. 20 is a top view of the second stair of the turning stair set of FIG. 16.

FIG. 21 is a side view of the modular stair tread overlay for the third stair of the turning stair set of FIG. 16.

FIG. 22 is a top view of the third stair of the turning stair set of FIG. 16.

FIG. 23 is a front view of a curved stair case.

FIG. 24 side view of a modular stair tread overlay for a stair tread of a curved stair case.

FIG. 25 is a top view of a stair tread of the curved stair case of FIG. 23.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is directed to a modular stair tread overlay system and method for giving a finished or decorative appearance to a set of stairs 2 (see FIG. 1), eliminating the need to tear out and replace existing stairs. FIG. 1 shows an existing set of stairs 2. The stair set 2 may be open along one end/side opposite wall or the stairs 2 may be closed along both sides. The stairs have a series of treads 10 and risers 15, which are framed by a stringer 20. Unfinished stairs 2 are typically constructed out of a wood composite material such as plywood, fiber board, oriented strand board or the like. The stairs 2 typically are covered by carpet, although in certain cases, such as stairs to an unfinished basement, they may be left exposed.

Now referring to FIGS. 2 and 3, in the present embodiment, a modular stair tread overlay system 5 is shown. The modular stair tread overlay system 5 generally comprises a stair tread cover 30 and a two pieces nose capping 35, 40. The stair tread cover and the two pieces nose capping 35, 40 are typically interconnected using a tongue 50 and groove 55 mechanism. The tongue 50 and groove 55 joint provide a strong mechanical joint between the nosing portions and the tread 10. Adhesive may be applied at the tongue 50 and groove 55 joint to enhance the strength of the joint. In addition, the modular stair tread overlay may also comprise a riser cover 45. As such it is possible to entirely cover the original stair set. Although the riser cover 45 is generally installed onto an original riser 15, the riser cover 45 can be installed on its own, for instances, wherein the original stair set were not completed with risers 15.

An exemplary embodiment of a finished stair overlay 5 is shown in FIGS. 3. The stair tread cover 30 is generally installed onto the stair tread 10. The size of the stair tread cover should ideally be chosen with regards to the length of the stair tread 10. The stair tread cover 30 should be slightly longer than the original stair tread 10 as to cover the nose portion 25 of the original stair tread 10.

As best shown in FIG. 3, after having installed the stair tread cover, the capping portion shall be installed. The stair tread overlay system 5 generally comprises a two pieces nose capping portion which size will typically determine the overall aspect of the remodeled stair set. As such depending on the requirements or the preferences of the home owner, the height of the nose capping portion 35, 135, 235 and 335 may be adjusted (see FIGS. 6-8). The height of the nose capping portion 35, 135, 235 and 335 may be optimized to minimally overlap original stair tread nose 25 or may be oversized compared to the original stair tread nose 25. A longer first nose capping portion 35, 135, 235, 335 will result in a thicker stair stead (see FIGS. 6-8). Such thicker stair nose will generally be chosen in contemporary houses to give an innovative look to the stair set.

As explained above, the thickness of the stair is first determined by the size of the nose capping portion 35. Then, based on the determined thickness, r it shall be determine if the stair tread overlay 5 shall be covered by a riser 45. If no riser cover 45 is required for a specific stair or step, the corresponding second nose capping portion 40 shall be sized to at least cover the length from the first nose capping portion 35, 135, 235, 335 to the original riser 15. If a riser cover 45 is required for a specific step or for the stair, the length of the second nose capping portion 40 shall be equal to the length between the outside of the riser cover 45 and the inside of the first nose capping portion 35.

Still referring to FIG. 3, the modular stair tread overlay system 5 is typically secured onto the tread 10 with the use of an adhesive. However, the securing of the modular stair tread overlay system 5 can be achieved using screws or nails or a combination of adhesive and screws and/or nails. The choice of securing means will generally be function of the type of material covering the original stair set. For instance, a stair tread overlay system 5 being installed on a original stair set covered with industrial carpet shall be affixed with adhesive instead of screws.

The first nose capping portion 35, 135, 435 and 535 may contain a design or contour as best shown in FIGS. 4-6. In another embodiment, the first nose capping portion 35 may be customized to fit any particular style of staircase.

Now referring to FIGS. 9 and 10, in another embodiment, a reinforced design may be installed wherein the inside of the first nose capping portion 35 is configured to match the shape of the tread nose 60 and 160.

As best shown in FIG. 11, should the existing stairs have an exposed side edge, the modular stair tread overlay system 5 may further comprises one or more side caps 70. The side cap 70 may be installed on both or either sides of the stair tread.

Now referring to FIGS. 12 and 13, in a further embodiment, the modular stair tread overlay system 5 may be molded into a unitary piece 100. An additional embodiment of the present invention may comprise a riser 110 as an add-on component or as an integrated part of the unitary stair tread overlay 120. Such an embodiment would generally be manufactured using composite material such as polymers.

Now referring to FIGS. 14 and 15, in another embodiment, the tongue 50 and groove 55 (as shown in FIG. 3) of the modular stair tread overlay system 5 may comprise one or more interlocking mechanism 150, 155. In such an embodiment, the nose capping portion 35 may be installed without using any adhesive. Such interlocking mechanism may allow the first capping portion 35 to be easily changed or replaced with another one.

In a further embodiment, the riser cover 45 may be attached to the tread cover 30 and nose capping portions 35, 135, 235 or 335 by a tongue and groove mechanism. Accordingly, the modular parts may be interlocked by yielding a modular stair tread system. Such a configuration advantageously minimizes the required skills for installation. For instance, in order to be secured to the original stair set, the interlocking parts may only require the addition of small quantities.

Now referring to FIGS. 16-22, in another embodiment, the modular stair tread overlay 5 is configured to cover a stair set wherein the stair case comprises a 90 degree turn. A modular stair tread overlay 210, 215, 220 in accordance with the present invention as shown in FIG. 16 is designed to cover a stair case comprising a 90 degree turn. Although the present embodiment refers to a 90 degree turn, one skilled in the art shall understand that the present invention may be adapted to most stair set comprising turns of any angle. In another embodiment, the modular stair tread overlay 210, 215, 220 invention may be adapted to be installed onto curved staircases as shown in FIG. 23-25.

Though the present invention may be best utilized to transform an unfinished set of stairs into a more polished and better looking staircase, one may advantageously install a modular stair tread overlay to provide a decorative or new appearance to such staircases. A worn set of finished stairs may be trimmed or sanded as necessary and the overlay attached thereto to provide a new finished appearance. The overlay may also be used in new construction. A simple unfinished staircase may be constructed and the overlay placed over top of it as described above. This will provide a lower cost alternative stair case which could be easily changed or replaced in the future as needed.

While illustrative and presently preferred embodiments of the invention have been described in detail hereinabove, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art. 

1. A modular stair tread overlay system for giving a finished or decorative appearance to a set of existing stairs steps, the modular stair tread overlay system comprising: a. a stair tread overlay comprising an elongated, substantially planar top tread portion for fitting over a top planar portion of the existing stair step; and b. a nose capping member extending from an edge of the top tread portion for fitting over the nose of the stair step tread;  wherein the nose capping member comprises a first nose capping piece and a second nose capping piece.
 2. A modular stair tread overlay system as claimed in claim 1, wherein the first and second nose capping portion are interconnected using a tongue and groove mechanism and wherein the first nose capping portion and the stair tread overlay are interconnected using a tongue and groove mechanism.
 3. A modular stair tread overlay system as claimed in claim 1, wherein the modular stair tread overlay system further comprises a riser cover having the second nose capping member secured thereto.
 4. A modular stair tread overlay system as claimed in claim 1, wherein the first nose capping piece is removably secured to the stair tread overlay and to the second nose capping piece.
 5. A modular stair tread overlay system as claimed in claim 1, wherein the stair tread overlay and the nose capping member are made from wood of different species.
 6. A modular stair tread overlay system as claimed in claim 1, wherein the first nose capping piece is substantially larger than twice the width of the nose of an existing tread.
 7. A modular stair tread overlay system as claimed in claim 1, wherein the tongue and groove provide an interlocking mechanism.
 8. A modular stair tread overlay system as claimed in claim 1, wherein the modular stair tread overlay system further comprises an interchangeable first capping portion.
 9. A modular stair tread overlay system as claimed in claim 1, wherein the first nose capping portion has a reinforced design; and wherein the inside of the first nose capping portion is configured to match the shape of the tread nose.
 10. A modular stair tread overlay system as claimed in claim 1, wherein the modular stair tread overlay system further comprises at least one side cap to cover an exposed side of a stair tread and wherein the side cap is secured to the stair treat overlay and to the nose capping member.
 11. A modular stair tread overlay system as claimed in claim 1, wherein the first nose capping portion of the modular stair tread overlay system has a rounded outer surface.
 12. A modular stair tread overlay system as claimed in claim 1, wherein the modular stair tread overlay system is made from composite material.
 13. A method for remodeling a stair set using a the modular stair tread overlay system comprising a stair tread overlay comprising an elongated, substantially planar top tread portion for fitting over a top planar portion of the existing stair step and a nose capping member extending from an edge of the top tread portion for fitting over the nose of the stair step tread wherein the nose capping member comprises a first nose capping piece and a second nose capping piece, the method comprising the step of: a. securing the stair tread cover over the existing stair tread; b. securing the first nose capping piece to the second nose capping piece; c. securing one side of the secured first and second nose capping piece to the stair tread cover; and d. securing the second side of the secured first and second nose capping piece to the riser of the stair.
 14. The method of claim 13 wherein the modular stair tread overlay system further comprises a riser cover and wherein the method further comprises the steps to: a. securing the riser cover to the riser of the stair; b. securing the second nose member to the riser cover.
 15. The method of claim 14 wherein the first capping portion is interchangeable and wherein the method further comprises the steps to: a. removing the secured first capping portion; b. securing the interchangeable first capping portion.
 16. The method of claim 14 wherein the modular stair tread overlay system further comprises at least one side cap to cover an exposed side of the stair tread and wherein the method further comprises the step to secure the the side cap to the stair tread overlay and to the nose capping. 